Xantrex 3000 User's Manual
Contents
1. 2 2 DC Panel 2 4 3 Installation Designing Your Installation 3 1 Installation Codes 3 3 Calculating Battery Requirements 3 3 Choosing an Effective Charging System 3 3 Choosing an Appropriate Location 3 4 Calculating Cable Sizes 3 5 Calculating Size of DC Input Cables 3 5 Calculating Size of Chassis Ground Cable 3 6 Calculating Fuse Circuit Breaker Size 3 7 Installing the inverter 3 8 Safety Instructions 3 8 Installation Tools and Materials 3 8 Tools 3 8 Materials 3 8 Overview of Installation Steps 3 9 975 0128 01 01 ix Contents Installing the Remote On Off Switch 3 9 Mounting the Inverter 3 10 AC Connections 3 11 Connecting the Chassis Ground2. 3 11 Grounding Locations 3 12 Chassis Ground Lug 3 12 DC Disconnects and Over Current Devices 3 12 Connecting the DC Cables 3 13 4 Operation Turning the Inverter On and Off 4 1 Operating Several Loads at Once 4 1 Turning the Inverter Off Between Charges 4 2 Display Screen 4 2 Operating Limits 4 3 Power Output 4 3 Input Voltage 4 3 Inverter Loads 4 4 High Surge Loads 4 4 Trouble Loads 4 4 Routine Maintenance 4 5 Recharging Your Batteries 4 5 5 Troubleshooting Common Problems 5 1 Buzz in Audio Equipment 5 1 Television Reception 5 1 Troubleshooting Reference
3. and terminal surface Assemble exactly as shown Copper Compression Lug Aluminum Box Lug Figure 3 5 DC cable lug examples 975 0128 01 01 Consult Figure 3 1 Configuration for Normal Loads on page 3 2 or Figure 3 2 Configuration for Heavy Loads on page 3 2 for additional details that are specific to your installation To make the DC connections l Cut the cables to the correct length with enough insulation stripped off so you can properly install the type of terminals you will be using The terminals on the DC end are designed to fit up to 500 MCM crimp on ring terminals either AMP or ILSCO or box connectors Attach the connectors to both cables If using compression lugs attach the terminals to both cables using the crimp tool recommended by the manufacturer of the ring terminals There must be no stray wire strands protruding from the terminal If using box lugs attach the lug to the XPower Inverter 3000 Plus first then insert the wire and tighten the set screw to the torque recommended by the lug manufacturer 3 Route the DC supply cables from the battery bank to the inverter Installation 4 Install a fuse and disconnect switch or breaker between the inverter and the battery Ensure that the disconnect switch or breaker is turned off before installing They must be installed in the positive side of the DC circuit as close as possible to the battery This protects your battery and wiring in c
4. The Remote On Off switch can be plugged into the remote switch connector port on the front of the inverter The remote switch lets you turn the inverter on and off from a convenient location up to 20 feet 6 m away from the inverter Figure 2 1 XPower Remote On Off Switch Dimensions of Remote On Off Switch Length 2 5 05 cm Width 2 6 40 cm Depth 1 2 54 cm Cable Length 20 6 m Features AC Panel 10 11 Figure 2 2 AC Panel 12 Feature Description 1 On Off Switch turns the inverter s control circuit on and off This switch is not a power disconnect switch Disconnect AC and DC power before working on any circuits connected to the inverter Fault light red indicates the inverter has shut down due to inverter overload or over temperature Power light green indicates the inverter is operating Display Function Button Press this to display battery voltage battery current and AC output power Status indicator lights VOLTAGE CURRENT AC POWER When lit each light indicates which status is being displayed 2 2 975 0128 01 01 975 0128 01 01 AC Panel Feature Description 6 Status Display Shows Voltage Current or AC Power VOLTAGE Indicates battery power at the input terminal of the inverter in volts V CURRENT Indicates current drawn from the battery by the inverter in amps A AC POWER In
5. power y Xantrex XPower Inverter 3000 Plus Owner s Guide About Xantrex Xantrex Technology Inc is a world leading supplier of advanced power electronics and controls with products from 50 watt mobile units to one MW utility scale systems for wind solar batteries fuel cells microturbines and backup power applications in both grid connected and stand alone systems Xantrex products include inverters battery chargers programmable power supplies and variable speed drives that convert supply control clean and distribute electrical power Trademarks XPower is a trademark of Xantrex International Xantrex is a registered trademark of Xantrex International Other trademarks registered trademarks and product names are the property of their respective owners and are used herein for identification purposes only Notice of Copyright XPower 3000 Plus Owner s Guide December 2003 Xantrex International All rights reserved Disclaimer UNLESS SPECIFICALLY AGREED TO IN WRITING XANTREX TECHNOLOGY INC XANTREX a MAKES NO WARRANTY AS TO THE ACCURACY SUFFICIENCY OR SUITABILITY OF ANY TECHNICAL OR OTHER INFORMATION PROVIDED IN ITS MANUALS OR OTHER DOCUMENTATION b ASSUMES NO RESPONSIBILITY OR LIABILITY FOR LOSS OR DAMAGE WHETHER DIRECT INDIRECT CONSEQUENTIAL OR INCIDENTAL WHICH MIGHT ARISE OUT OF THE USE OF SUCH INFORMATION THE USE OF ANY SUCH INFORMATION WILL BE ENTIRELY AT THE USER S RISK Date and Revisio
6. A Power Consumption Watts B Operating Time per Day Hours TV amp VCR 200 W 2 hours 400 Wh Microwave oven 1400 W 15 min 1 4 hour 350 Wh 3 lamps 60 W each 180 W 4 hours 720 Wh Coffee maker Steam iron 600 W 15 min 1 4 hour 700 W 6 min 1 10 hour 150 Wh 70 Wh Total daily watt hours of AC load 1690 Wh x Number of days between charges 3 Total watt hours of AC load between charges 5070 Wh Battery Ah used between charges divide by 10 507 Ah Recommended Battery Bank Size in Ah multiply by 2 1014 Ah B 4 This example illustrates how quickly your battery needs can escalate To reduce the required battery size you can conserve energy by eliminating or reducing the use of some loads or by re charging more frequently When sizing your battery resist the temptation to skip the last step of this calculation multiplying by 2 More capacity is better since you will have more reserve capacity be better able to handle large loads and surge loads and your battery won t be discharged as deeply Battery life is directly dependent on how deeply the battery is discharged The deeper the discharge the shorter the battery life 975 0128 01 01 Estimating Battery Requirements Battery Sizing Worksheet Use the following worksheet to calculate your battery needs To ensure sufficient battery capacity be generous when estimating the op
7. C3 Charging From Alternative Energy Sources C3 Warranty and Product Information WA 1 975 0128 01 01 xi xii Introduction The XPower Inverter 3000 Plus has been designed to give you quality power ease of use and reliability Please take a few moments to read this chapter to familiarize yourself with the main performance features and protection features Quality Power The XPower Inverter 3000 Plus is designed for use in recreational vehicles RVs light and heavy duty truck applications and other in vehicle applications The inverter provides up to 2500 W of continuous power It is designed to handle loads such as microwaves refrigerators freezers circular saws and small air compressors The inverter s high surge capability lets you handle many hard to start loads including large TVs refrigerators and freezers The inverter s low standby battery demand means you don t have to worry about excessive drain on your battery if you leave the inverter on for a few days When the inverter is on but no power is being supplied to a load the inverter draws less than 600 mA from the battery The cooling fan in the inverter is thermally activated and comes on when the inverter becomes warm The fan turns off automatically after the inverter has cooled Introduction Ease of Use Superior features and rugged durability have been combined with ease of us
8. Length of time inverter has been installed Battery battery bank size OO oO Battery type e g flooded sealed gel cell AGM DC wiring size and length Alarm sounding Description of indicators on front panel Appliances operating when problem occurred OU O OF O Description of problem WA 6 975 0128 01 01
9. 5 2 A Specifications Electrical Performance A 1 Physical Specifications A 1 x 975 0128 01 01 Contents B Battery Types Battery Types B 1 Automotive Starting Batteries B 1 Deep Cycle Batteries B 1 Battery Size B 2 Estimating Battery Requirements B 3 Battery Sizing Example B 4 Battery Sizing Worksheet B 5 Using Multiple Batteries B 6 Two Batteries Connected In Parallel B 6 Two Separate Battery Banks B 6 Battery Tips B 7 C Alternators and Charging Systems Charging System Requirements Cl Charging With an Engine Alternator C2 Using a Standard Vehicle Alternator C2 Using an Alternator Controller C2 Using a High Output Alternator C2 Charging From AC Power
10. CYCLE AUXILIARY BATTERY ISOLATOR FROM ALTERNATOR OR CHARGER Figure 3 1 Configuration for Normal Loads TO VEHICLE FROM ALTERNATOR OR CHARGER GROUND TO VEHICLE CHASSIS VEHICLE STARTING BATTERY BATTERY ISOLATOR FUSE OR CIRCUIT BREAKER FUSE OR CIRCUIT BREAKER F DEEP CYCLE BATTERY DEEP CYCLE BATTERY ALL 1 BATTERY SELECTOR SWITCH OFF 2 GROUND VEHICL CHASS TO DC LOADS DEEP CYCLE BATTERY DEEP CYCLE BATTERY FUSE OR CIRCUIT BREAKER FUSE OR CIRCUIT BREAKER DICONNECT BATTERY SELECTOR SWITCH GROUND TO VEHICLE CHASSIS Configuration for Heavy Loads 975 0128 01 01 Designing Your Installation Installation Codes Governing installation codes vary depending on the location and type of installation Electrical installations must meet local and national wiring codes and should be performed by a qualified electrician In residential applications electrical codes do not allow permanent connection of AC distribution wiring to the inverter s AC output receptacles The receptacles are intended for temporary as needed connection of cord connected loads only Calculating Battery Requirements Battery type and battery size strongly affect the performance of the inverter Therefore you need to identify the type of loads your inverter will be powering and how much
11. V or shut off AN CAUTION Never operate the inverter directly from an alternator To work properly the inverter must be connected to a battery or a well regulated high current DC power supply Alternators and Charging Systems Charging With an Engine Alternator Read the following information to determine whether your vehicle s standard alternator will be adequate by itself whether you should install an alternator controller or whether you need a high output alternator Using a Standard Vehicle Alternator A typical engine alternator 12 V may not be able to meet the requirements outlined above if your system uses large capacity batteries Alternators are typically rated for the current they can deliver when they are cold When in use alternators heat up and their output current capability drops by as much as 25 Therefore standard alternators with ratings of 40 105 A only deliver a maximum of 30 80 A in actual use and deliver even less as battery voltage rises Many alternators cannot produce more than 13 6 V when they are hot As a result a standard alternator may not be able to charge a large battery quickly and completely Two solutions are to install an alternator controller or to install a high output alternator Using an Alternator Controller If your regular alternator is inadequate you can install an alternator controller that bypasses the voltage regulator and boosts the alternator s output voltage d
12. clearance compartment Overheating may result The inverter must only be installed in a location that is Dry Cool Ventilated Safe Close to battery Protected from battery gases Do not allow water or other liquids to drop or splash on it Ambient air temperature should be between 0 and 40 C 32 and 105 F the cooler the better within this range Allow at least 3 76 mm of clearance around the inverter for air flow Ensure that the ventilation openings on the DC end and on the bottom of the inverter are not obstructed Do not install the inverter in the same compartment as batteries or in any compartment capable of storing flammable liquids like gasoline Do not use excessive DC cable lengths they increase wire resistance and reduce input power Longer AC wires are preferable to longer DC wires wire resistance and therefore voltage drop is less and the cost is lower Do not mount the inverter where it will be exposed to gases produced by batteries Battery gases are corrosive and prolonged exposure to battery gases will damage the inverter 975 0128 01 01 Designing Your Installation Calculating Cable Sizes To operate safely and effectively the XPower Inverter 3000 Plus needs proper cables and fuses Because the XPower Inverter 3000 Plus has low voltage and high current input it is essential that you use low resistance wiring between the battery and the inverter to deliver the maximum amount of
13. inexpensive stereo systems may emit a buzzing noise from their loudspeakers when operated from the inverter This occurs because the power supply in the audio system does not adequately filter the modified sine wave produced by the inverter The only solution is to use a sound system that has a higher quality power supply Television Reception When the inverter is operating it can interfere with television reception on some channels If interference occurs try the following 1 Make sure that the chassis ground screw on the rear of the inverter is solidly connected to the ground system of your vehicle 2 Make sure that the television antenna provides an adequate snow free signal and that you are using good quality cable between the antenna and the television 3 Keep the cables between the battery and the inverter as short as possible and twist them together with two to three twists per foot This minimizes radiated interference from the cables 4 Move the television as far away from the inverter as possible Do not operate high power loads with the inverter while the television is on 5 1 Troubleshooting Troubleshooting Reference WARNING Electrical shock and burn hazard Do not disassemble the inverter It does not contain any user serviceable parts Attempting to service the inverter yourself could result in an electrical shock or burn Table 5 1 Troubleshooting Reference Error Warning Code
14. may apply to that particular facility WA 4 975 0128 01 01 Out of Warranty Service If the warranty period for your XPower Inverter 3000 Plus has expired if the unit was damaged by misuse or incorrect installation if other conditions of the warranty have not been met or if no dated proof of purchase is available your inverter may be serviced or replaced for a flat fee To return your XPower Inverter 3000 Plus for out of warranty service contact Xantrex Customer Service for a Return Material Authorization RMA number and follow the other steps outlined in Return Procedure on page WA 4 Payment options such as credit card or money order will be explained by the Customer Service Representative In cases where the minimum flat fee does not apply as with incomplete units or units with excessive damage an additional fee will be charged If applicable you will be contacted by Customer Service once your unit has been received 975 0128 01 01 WA 5 Warranty and Product Information Information About Your System As soon as you open your XPower Inverter 3000 Plus package record the following information and be sure to keep your proof of purchase O Serial Number on DC end O Purchased From O Purchase Date If you need to contact Customer Service please record the following details before calling This information will help our representatives give you better service Type of installation e g RV truck
15. may find it more convenient to have the crimp connectors installed onto the DC cable by the store that sells you the cable and or connectors Materials The following checklist is a general list of required materials Optional components are indicated by an e Four corrosion resistant fasteners sized 10 or larger for mounting the inverter e Copper DC input cable as calculated in Table 3 1 Recommended DC Input Wire Sizes amp Lengths on page 3 6 e Two 5 16 ring terminals sized for the cable diameter or box lug terminals to connect the DC cables to the DC cabling terminal e Lugs and terminals to connect the DC cables that connect to the battery fuse holder s and disconnect switch 3 8 975 0128 01 01 Installing the inverter DC fuse s as calculated in Calculating Fuse Circuit Breaker Size on page 3 7 and fuse holder s Copper chassis ground cable as calculated in Table 3 2 Recommended Chassis Ground Cable sizes on page 3 6 Battery isolator if connecting to a multiple battery system Battery disconnect switch Battery selector switch Alternator controller High output alternator Consult Appendix B Battery Types and Sizes and Appendix C Alternators and Charging Systems to determine whether you need these components Overview of Installation Steps These are the five steps for installing your inverter Do not proceed with installation until you have read Designing Your Inst
16. t cause a spark Precautions for Using Rechargeable Appliances AN CAUTION Equipment damage 975 0128 01 01 Most rechargeable battery operated equipment uses a separate charger or transformer that is plugged into an AC receptacle and produces a low voltage charging output Some chargers for small rechargeable batteries can be damaged if connected to the XPower Inverter 3000 Plus Do not use the following with the XPower Inverter 3000 Plus e Small battery operated appliances like flashlights razors and night lights that can be plugged directly into an AC receptacle to recharge Some chargers for battery packs used in power hand tools These affected chargers display a warning label stating that dangerous voltages are present at the battery terminals vii viii Contents Important Safety Instructions Explosive gas precautions vi Precautions When Working With Batteries vi Precautions for Using Rechargeable Appliances vii 1 Introduction Quality Power 1 1 Ease of Use 1 2 Comprehensive Protection 1 2 2 Features Remote On Off Switch 2 1 Dimensions of Remote On Off Switch 2 1 AC Panel
17. the following in parallel e batteries made by different manufacturers e different types of batteries e batteries that have different Ah ratings Decreased battery life and improper charging will result Two Separate Battery Banks If you need more than two batteries or are using different makes or models of batteries Xantrex recommends that you install two separate battery banks and a battery selector switch Figure 3 2 Configuration for Heavy Loads on page 3 2 shows two separate battery banks and a battery selector switch This configuration is recommended for heavy duty applications By installing a battery selector switch you can select between the two battery banks use both banks in parallel or disconnect both banks from the load Battery selector switches are available at marine and RV dealers 975 0128 01 01 Battery Tips Battery Tips WARNING Review Precautions When Working With Batteries on page vi before you work with the batteries in your system Explosive Corrosive Gases Temperature Sensitivity Discharged Batteries Electrolyte Level 975 0128 01 01 Lead acid batteries may emit hydrogen gases oxygen and sulfuric acid fumes when recharging To reduce the risk of explosion e Vent the battery compartment to prevent the accumulation of gases e Do not install electronic or electrical equipment in the battery compartment e Do not smoke or use an open flame when wor
18. the removal installation or troubleshooting of the customer s electrical systems This warranty does not apply to and Xantrex will not be responsible for any defect in or damage to a the product if it has been misused neglected improperly installed physically damaged or altered either internally or externally or damaged from improper use or use in an unsuitable environment b the product if it has been subjected to fire water generalized corrosion biological infestations or input voltage that creates operating conditions beyond the maximum or minimum limits listed in the Xantrex product specifications including high input voltage from generators and lightning strikes c the product if repairs have been done to it other than by Xantrex or its authorized service centers hereafter ASCs d the product if it is used as a component part of a product expressly warranted by another manufac turer e the product if its original identification trade mark serial number markings have been defaced altered or removed WA 2 975 0128 01 01 Disclaimer Product THIS LIMITED WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY PROVIDED BY XANTREX IN CONNECTION WITH YOUR XANTREX PRODUCT AND IS WHERE PERMITTED BY LAW IN LIEU OF ALL OTHER WARRANTIES CONDITIONS GUARANTEES REPRESENTATIONS OBLIGATIONS AND LIABILITIES EXPRESS OR IMPLIED STATUTORY OR OTHERWISE IN CONNECTION WITH THE PRODUCT HOWEVER ARISING WHETHER BY CONTRACT TORT NEGL
19. to supply e The serial number of your product Information about the installation and use of the unit Information about the failure and or reason for the return e A copy of your dated proof of purchase Record these details in Information About Your System on page WA 6 Return Procedure 1 Package the unit safely preferably using the original box and packing materials Please ensure that your product is shipped fully insured in the original packaging or equivalent This warranty will not apply where the product is damaged due to improper packaging 2 Include the following e The RMA number supplied by Xantrex Technology Inc clearly marked on the outside of the box e A return address where the unit can be shipped Post office boxes are not acceptable e A contact telephone number where you can be reached during work hours e A brief description of the problem 3 Ship the unit prepaid to the address provided by your Xantrex customer service representative If you are returning a product from outside of the USA or Canada In addition to the above you MUST include return freight funds and are fully responsible for all documents duties tariffs and deposits If you are returning a product to a Xantrex Authorized Service Center ASC A Xantrex return material authorization RMA number is not required However you must contact the ASC prior to returning the product or presenting the unit to verify any return procedures that
20. tools kitchen appliances and other loads may be damaged e Some chargers for small rechargeable batteries can be damaged See Precautions for Using Rechargeable Appliances on page vii for details e Metal halide arc HMD lights can be damaged Ifyou are unsure about powering any device with the inverter contact the manufacturer of the device 975 0128 01 01 Routine Maintenance Routine Maintenance Minimal maintenance is required to keep your inverter operating properly Periodically you should e Clean the exterior of the inverter with a damp cloth to prevent the accumulation of dust and dirt e Ensure that the DC cables are secure and fasteners are tight e Make sure ventilation openings on the AC and DC panels of the inverter are not clogged Recharging Your Batteries When possible recharge your batteries when they are about 50 discharged or earlier This gives the batteries a much longer life cycle than recharging when they are almost completely discharged 975 0128 01 01 4 5 Troubleshooting Chapter 5 will help you identify the source of most problems that can occur with the inverter If you have a problem with the inverter please review this chapter before contacting place of purchase If you are unable to solve a problem and need to contact place of purchase record the information in the form Information About Your System on page WA 6 Common Problems Buzz in Audio Equipment Some
21. 0707 975 0128 01 01 5 4 Specifications Appendix A contains electrical performance and physical specifications for the inverter Electrical Performance Output power at 25 C 77 F ambient temperature and 12 V de input e Maximum continuous output power e 5 minute rating 2500 W 3000 W Output voltage 115 VAC RMS 5 Output waveform Modified sine wave Output frequency 60 Hz 4 Hz Input voltage 10 5 15 0 VDC Low battery alarm 11 0V Low battery cutout 10 5 V Optimum efficiency 90 No load current draw lt 0 6 A de Physical Specifications Length 18 1 2 47 cm Width 8 20 cm Height 6 1 4 16 cm Weight 20 lb 9 kg Specifications are subject to change without notice Battery Types The information in Appendix B will help you to select connect and maintain batteries that are most appropriate for your application The batteries that you use strongly affect the performance of the XPower 3000 It is important to connect the inverter to the correct size and type of battery Battery Types Automotive Starting Batteries The lead acid battery you are most familiar with is probably the starting battery in your vehicle An automotive starting battery is designed to deliver a large amount of current for a short period of time so it can start your engine Only a small portion of the battery s capacity is used when starting the engine and the sp
22. IGENCE PRINCIPLES OF MANUFACTURER S LIABILITY OPERATION OF LAW CONDUCT STATEMENT OR OTHERWISE INCLUDING WITHOUT RESTRICTION ANY IMPLIED WARRANTY OR CONDITION OF QUALITY MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE TO THE EXTENT REQUIRED UNDER APPLICABLE LAW TO APPLY TO THE PRODUCT SHALL BE LIMITED IN DURATION TO THE PERIOD STIPULATED UNDER THIS LIMITED WARRANTY IN NO EVENT WILL XANTREX BE LIABLE FOR ANY SPECIAL DIRECT INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES LOSSES COSTS OR EXPENSES HOWEVER ARISING WHETHER IN CONTRACT OR TORT INCLUDING WITHOUT RESTRICTION ANY ECONOMIC LOSSES OF ANY KIND ANY LOSS OR DAMAGE TO PROPERTY ANY PERSONAL INJURY ANY DAMAGE OR INJURY ARISING FROM OR AS A RESULT OF MISUSE OR ABUSE OR THE INCORRECT INSTALLATION INTEGRATION OR OPERATION OF THE PRODUCT Exclusions If this product is a consumer product federal law does not allow an exclusion of implied warranties To the extent you are entitled to implied warranties under federal law to the extent permitted by applicable law they are limited to the duration of this Limited Warranty Some states and provinces do not allow limitations or exclusions on implied warranties or on the duration of an implied warranty or on the limitation or exclusion of incidental or consequential damages so the above limitation s or exclusion s may not apply to you This Limited Warranty gives you s
23. TION The XPower 3000 must only be connected to batteries with a nominal output voltage of 12 volts The XPower 3000 will not operate from a 6 volt battery and will be damaged if connected to a 24 volt battery Battery Reserve Capacity Amp hour Ah Capacity Battery size or capacity is as important as the battery type for efficient operation of your loads Xantrex recommends that you purchase as much battery capacity as possible A number of different standards are used to rate battery energy storage capacity Automotive and marine starting batteries are normally rated in cranking amps This is not a relevant rating for continuous loads like an inverter Deep cycle batteries use a more suitable rating system either amp hours Ah or reserve capacity in minutes Battery reserve capacity is a measure of how long a battery can deliver a certain amount of current usually 25 amps For example a battery with a reserve capacity of 180 minutes can deliver 25 amps for 180 minutes before it is completely discharged Amp hour capacity is a measure of how many amps a battery can deliver for a specified length of time usually 20 hours For example a typical marine or RV battery rated for 100 Ah can deliver 5 amps for 20 hours 5 A x 20 hours 100 Ah 975 0128 01 01 Estimating Battery Requirements This same battery can deliver a higher or lower current for less or more time limited approximately by the 100 Ah figu
24. allation starting on page 3 1 l 2 3 4 5 Install the Remote On Off Switch Mount the inverter Connect the AC cables Connect the chassis ground Connect the DC cables Installing the Remote On Off Switch The Remote On Off switch can be plugged into the remote switch jack on the front of the inverter The remote switch lets you turn the inverter on and off from a convenient location up to 20 feet 6 m away from the inverter 975 0128 01 01 Installation Mounting the Inverter Do not mount the inverter under the hood of your vehicle See Choosing an Appropriate Location on page 3 4 To mount the inverter 1 Make sure the On Off switch is in the Off position 2 Select an appropriate mounting location and orientation The inverter must be oriented in one of the following ways e Horizontally on a vertical surface Do not mount with the fan pointing up or down e Ona horizontal surface e Under a horizontal surface Figure 3 3 Approved Mounting Orientations 3 Hold the inverter against the mounting surface mark the positions of the mounting screws and then remove the inverter Pilot drill the four mounting holes Fasten the inverter to the mounting surface using corrosion resistant fasteners sized 10 or larger 975 0128 01 01 Installing the inverter AC Connections You can plug your AC loads directly into the receptacles on the inverter front panel Output power to eac
25. ase of accidental shorting See Calculating Fuse Circuit Breaker Size on page 3 7 5 Attach one connector on the positive cable to the positive DC terminal on the DC end and then attach the other connector to the POSITIVE terminal on the fuse or breaker AN CAUTION Reverse polarity DC power connections to the inverter must be positive to positive and negative to negative A reverse polarity connection positive to negative will blow a fuse in the inverter and may permanently damage the inverter The fuse is not user replaceable and the inverter may need to be returned for servicing Damage caused by a reverse polarity connection is not covered by your warranty Observe the polarities carefully while completing the installation Use a wrench to tighten to a torque of 216 240 inch pounds 24 27 Nm Test that the cable is secure CAUTION Do not over tighten the nut on the DC input terminals Damage to the DC input terminals may result CAUTION Do not remove the terminal nut CAUTION Loose connections cause excessive voltage drop and may cause overheated wires and melted insulation 975 0128 01 01 975 0128 01 01 6 10 11 12 Connecting the DC Cables Connect one connector on the negative cable to the negative terminal on the DC end Before proceeding check that cable polarity is correct and then connect the other end of the cable to the NEGATIVE terminal on the bat
26. dicates the output power from the inverter as a percentage of total available watts being utilized 7 Two 15 A Breakers 8 3 Prong AC Outlets Each outlet is protected by a 15 amp breaker 9 AC Knockout For hardwiring the inverter 10 Remote On Off Connector Port For connecting the Remote On Off Switch 11 Mounting Flanges front and rear allow you to mount the inverter permanently 12 Ventilation Openings must not be obstructed for the proper operation of the inverter When the inverter is mounted the ventilation opening on the DC panel must not point up or down Features DC Panel DO NOT INSTALL OR OPERATE ON OR OVER COMBUSTIBLE SURFACES CAUTION OUTPUT NON SINUSOIDAL REFER MANUAL a LS Figure 2 3 DC Panel 12 VDC 300A MAX BATTERY NEG u e Serial No GND Feature Description 1 Chassis Ground Lug connects to vehicle chassis DC grounding bus or to engine s negative bus Ventilation Opening must not be obstructed for the proper operation of the inverter When the inverter is mounted the ventilation opening on the DC panel must not point up or down Negative DC Cabling Terminal always connects to the cable connected to the negative terminal of the battery Positive DC Cabling Terminal always connects to the cable connected to the positive terminal of the battery Serial number of your inverter 975 0128 01 01 Installation Chap
27. e e The inverter is compact lightweight and easy to install e Loads can be powered directly from the AC outlets e Easy to read indicators on the front panel let you monitor system performance at a glance e Remote On Off switch lets you control the inverter from a convenient location up to 20 feet 6 m away while the inverter itself is mounted out of sight Comprehensive Protection The inverter is equipped with numerous protection features to guarantee safe and trouble free operation Low battery alarm Alerts you if the battery has become discharged to 11 0 V or lower Low battery voltage shutdown Shuts the inverter down automatically if the battery voltage drops below 10 5 V This feature protects the battery from being completely discharged High battery voltage shutdown Shuts the inverter down automatically if the input voltage rises to 15 V or more Overload shutdown Shuts the inverter down automatically if a short circuit is detected in the circuitry connected to the inverter s output or if the loads connected to the inverter exceed the inverter s operating limits Over temperature shutdown Shuts the inverter down automatically if its internal temperature rises above an acceptable level 1 2 975 0128 01 01 Features Chapter 2 Features describes the main features of the XPower Inverter 3000 Plus Familiarize yourself with them before installing and operating the inverter Remote On Off Switch
28. e input terminals of the inverter At low input currents this voltage is very close to the battery voltage At high input currents this voltage is lower than the battery voltage because of the voltage drop across the cable and DC connections The BATTERY CURRENT INDICATOR displays the current draw from the battery in amps It will not indicate current draw from other loads connected to the battery The OUTPUT POWER INDICATOR indicates the AC output power in kW 975 0128 01 01 Operating Limits Power Output Operating Limits The XPower Inverter 3000 Plus can deliver up to 2500 W continuous and up to 3000 W for five minutes The wattage rating applies to resistive loads such as incandescent lights Input Voltage The allowable inverter input battery voltage ranges are shown in the following table Operating Condition Voltage Range Comment Normal 10 5 15 V Optimum 12 0 13 0 V Performance Low Voltage Alarm 11 0 V or less The audible low battery alarm sounds Low Voltage less than 10 5 V The inverter shuts down to protect the Shutdown battery from being over discharged High Voltage 15 0 V or more The inverter shuts down to protect Shutdown itself from excessive input voltage 975 0128 01 01 Note Although the inverter incorporates over voltage protection it can still be damaged if input voltage exceeds 16 V Operation Inverter Loads The inverter will operate most AC loads with
29. ell as its products and services at www xantrex com iv 975 0128 01 01 Important Safety Instructions WARNING This chapter contains important safety and operating instructions Read and keep this Owner s Guide for future reference l Before installing and using the XPower Inverter 3000 Plus read all instructions and cautionary markings on the XPower Inverter 3000 Plus the batteries and all appropriate sections of this guide Do not expose the XPower Inverter 3000 Plus to rain snow spray or bilge water To reduce risk of fire hazard do not cover or obstruct the ventilation openings Do not install the XPower Inverter 3000 Plus in a zero clearance compartment Overheating may result Use only attachments recommended or sold by the manufacturer Doing otherwise may result in a risk of fire electric shock or injury to persons To avoid a risk of fire and electric shock make sure that existing wiring is in good condition and that wire is not undersized Do not operate the XPower Inverter 3000 Plus with damaged or substandard wiring Do not operate the XPower Inverter 3000 Plus if it has received a sharp blow been dropped or otherwise damaged in any way If the XPower Inverter 3000 Plus is damaged see the Warranty section Do not disassemble the XPower Inverter 3000 Plus It contains no user serviceable parts See Warranty for instructions on obtaining service Attempting to service the XPower Inverter 3000 Plus y
30. ent capacity is quickly recharged by the running engine The starting battery in your vehicle is not designed for repeated deep discharge cycles where the battery is almost completely discharged and then recharged If a starting battery is used in this kind of deep discharge service it will wear out very rapidly Deep Cycle Batteries Deep cycle batteries are designed for deep discharge service where they will be repeatedly discharged and recharged They are marketed for use in recreational vehicles boats and electric golf carts so you may see them referred to as RV batteries marine batteries or golf cart batteries For most applications of the XPower 3000 Xantrex recommends that you use one or more deep cycle batteries that are separated from the vehicle s starting battery by a battery isolator Battery Types A battery isolator is a solid state electronic circuit that allows equipment to be operated from an auxiliary battery without danger of discharging the vehicle s starting battery During vehicle operation the battery isolator automatically directs the charge from the alternator to the battery requiring the charge Figure 3 1 Configuration for Normal Loads on page 3 2 and Figure 3 2 Configuration for Heavy Loads on page 3 2 show a battery isolator in configurations for normal and heavy duty loads Battery isolators are available at marine and RV dealers and most auto parts stores Battery Size CAU
31. er on e Move the On Off switch to the Off position to turn the inverter off When the switch is Off the inverter draws a very low current from the battery CAUTION The inverter s On Off switch does not disconnect DC battery power from the inverter You must disconnect AC and DC power before working on any circuits connected to the inverter Operating Several Loads at Once If you are going to operate several loads from the inverter turn them on separately after you have turned the inverter on Turning loads on separately helps to ensure that the inverter does not have to deliver the starting current for all the loads at once and will help prevent an overload shutdown Operation Turning the Inverter Off Between Charges The inverter draws less than 600 mA from the battery with the On Off switch turned on and no load connected but left in this state the inverter will eventually discharge the battery To prevent unnecessary battery discharge turn the inverter off when you are not using it Display Screen Battery Voltage Indicator Battery Current Indicator Output Power Indicator You can monitor important status information on the LED light emitting diode display screen To select which information the screen displays press the Display Function button The VOLTAGE CURRENT and AC POWER lights indicate what information the screen is showing The BATTERY VOLTAGE INDICATOR indicates the DC voltage at th
32. erating time per day for each of the loads you will run Daily watt hours needed A Power B Operating Time for this appliance Appliance Consumption Watts per Day Hours A xB W hours Wh W hours Wh W hours Wh W hours Wh W hours Wh W hours Wh W hours Wh W hours Wh Total daily watt hours of AC load Wh x Number of days between charges Total watt hours of AC load between charges Wh Battery Ah used between charges divide by 10 Ah Recommended Battery Bank Size in Ah multiply by 2 Ah 975 0128 01 01 B 5 Battery Types Using Multiple Batteries As your power requirements increase you may need to use more than one battery to obtain sufficient capacity Read Two Batteries Connected In Parallel and Two Separate Battery Banks to determine whether two batteries or two battery banks are more appropriate for your applications Two Batteries Connected In Parallel Two identical batteries can be connected positive to positive and negative to negative in a parallel system A parallel system doubles capacity and maintains the voltage of a single battery Figure 3 1 Configuration for Normal Loads on page 3 2 shows a battery configuration suitable for normal loads Figure 3 2 Configuration for Heavy Loads on page 3 2 show a battery configuration that is recommended for heavy loads A CAUTION Do not connect
33. h receptacle is limited by a circuit breaker to 1500 Watts 15 A You may also make a permanent AC connection via the AC knockout This connection must be made in accordance with applicable electrical codes If you are not familiar with the applicable electrical codes and wiring practices we recommend you have the inverter installed by a qualified electrician Connecting the Chassis Ground The inverter has a lug connector labelled CHASSIS GND on the rear panel as shown in Figure 3 4 This lug is used to connect the chassis of the inverter to your system s DC grounding point as required by regulations for some installations Follow the guidelines in Grounding Locations to connect the inverter s chassis to the ground Use copper wire that is provided with green insulation Do not use the DC Ground Lug for your AC grounding DO NOT INSTALL OR OPERATE ON OR OVER COMBUSTIBLE SURFACES M 12 VDC 300A MAX BATTERY NEG BATTERY POS Figure 3 4 DC Panel Connections 975 0128 01 01 3 11 Installation WARNING Electrical Shock Hazard Never operate the inverter without properly connecting the chassis ground An electrical shock hazard could result from improper grounding Grounding Locations You must connect the chassis ground terminal to a grounding point Follow the installation guidelines below These guidelines assume you are using the code compliant DC supply cable and fuse sizes indicated in this ma
34. in its power rating of 2500 W However some appliances and equipment may be difficult to operate and other appliances may actually be damaged if you try to operate them with the inverter Please read High Surge Loads and Trouble Loads carefully High Surge Loads Trouble Loads Some induction motors used in freezers pumps and other motor operated equipment require high surge currents to start The inverter may not be able to start some of these motors even though their rated current draw is within the inverter s limits The inverter will normally start single phase induction motors rated at 3 4 horsepower or less If a motor refuses to start observe the BATTERY VOLTAGE INDICATOR while trying to start the motor If the indicator drops below 11 V while the inverter is trying to start the motor this low voltage condition may be why the motor won t start Make sure that the battery connections are good and that the battery is fully charged If the connections are good and the battery is charged but the voltage still drops below 11 V you may need to use a larger battery A CAUTION Some equipment may be damaged by the inverter s modified sine wave output Some appliances including the types listed below may be damaged if they are connected to the inverter e Electronics that modulate RF radio frequency signals on the AC line will not work and may be damaged e Speed controllers found in some fans power
35. input polarity Battery disconnect switch or breaker is off Code on Display Problem Possible Cause Solution 5 E03 Flashing Inverter is in Load applied is above Reduce the load if continuous Fault LED Flashing overload shutdown the continuous operation operation is required Alarm Beeping limit 6 E04 Flashing Inverter is in AL2 warning code is See solution under error 2 Fault LED Flashing thermal shutdown ignored See possible in this table Alarm Beeping causes under error 2 in this table 7 OS5 Flashing Output on inverter N A Remove the short circuit Fault LED Flashing is shortcircuit Alarm Beeping 8 N A Low output voltage You are using a Use a true RMS reading 96 VAC 104 VAC voltmeter that cannot voltmeter such as the Fluke accurately read the RMS 87 voltage of a modified sine wave 9 N A Low output voltage Low input voltage and Check the connections and ona true RMS the load is close to cable to see if the battery is reading voltmeter maximum allowable fully charged Recharge the power battery if it is low Reduce the load 10 N A No output voltage The inverter is off Turn the inverter on Check the wiring to the inverter Return the inverter The inverter has probably been damaged Have it repaired Damage caused by reverse polarity is not covered by the warranty Close battery disconnect switch or breaker Consumer Hotline 1 800 670
36. is the sum of the short circuit current ratings of all of the batteries connected in parallel For batteries connected in series the total short circuit current rating is equal to the short circuit rating of a single battery 2 Once you have determined the total short circuit current rating of your batteries pick the fuse circuit breaker s interrupt capacity based on the short circuit current calculated in step 1 3 Choose a fuse circuit breaker with a correct current rating Fuses can be bought at any marine supply store RV supply store or electrical products store 975 0128 01 01 3 7 Installation Installing the inverter Do not proceed with the installation of your inverter until you have read the section Designing Your Installation on page 3 1 The more thorough your planning the better your power needs will be met to achieve maximum performance from your inverter Safety Instructions Before you start to install the inverter e Review the Important Safety Instructions on page v e Do not attempt your own AC wiring unless you have the knowledge tools and experience to do a safe job A licensed electrician can install the inverter if you do not wish to do your own wiring e Read and follow all Warnings and Cautions in this chapter Installation Tools and Materials Tools e Wire stripper e Wrench for DC terminals Screwdriver Crimping tool for fastening lugs and terminals on DC cables You
37. king around batteries The capacity of lead acid batteries is temperature sensitive Battery capacity is rated at 77 F 25 C At 0 F 20 C the Ah capacity is about half the rated capacity You should consider temperature when designing your system e Low Temperatures If extremely low temperatures are expected where the inverter is going to be located you should consider a heated equipment room If the system is located in an unheated space an insulated battery enclosure is recommended High Temperatures The batteries should also be protected from high temperatures These can be caused by high ambient temperatures solar heating of the battery enclosure or heat released by a nearby engine or generator High battery temperatures shorten battery life and therefore you should ventilate the enclosure and use shade and insulation as appropriate Do not leave batteries in a discharged state for more than a day or two They will undergo a chemical process sulfation that can permanently damage the battery As well batteries self discharge over a period of three to six months and they should be recharged periodically even if they are not being used If your batteries are not the maintenance free type check the electrolyte level at least once a month Excessive fluid loss is a sign of overcharging Replenish the electrolyte using only distilled water Battery Types Battery Connections Battery State of Charge Co
38. n December 2003 Revision A Part Number 975 0128 01 01 Contact Information Telephone 1 800 670 0707 toll free North America 1 360 925 5097 direct Fax 1 800 994 7828 toll free North America 1 360 925 5143 direct Email customerservice xantrex com Web www xantrex com About This Guide Purpose The purpose of this Owner s Guide is to provide explanations and procedures for installing operating maintaining and troubleshooting the XPower Inverter 3000 Plus Scope The Guide provides safety guidelines detailed planning and setup information procedures for installing the inverter as well as information about operating and troubleshooting the inverter It does not provide details about particular brands of batteries You need to consult individual battery manufacturers for this information Audience The Guide is intended for anyone who needs to install and operate the XPower Inverter 3000 Plus About This Guide Conventions Used The following conventions are used in this guide WARNING Warnings identify conditions that could result in personal injury or loss of life CAUTION Cautions identify conditions or practices that could result in damage to the unit or other equipment Important These notes describe things which are important for you to know but not as serious as a caution or warning Related Information You can find more information about Xantrex Technology Inc as w
39. nnections to battery posts must be made with permanent connectors that provide a reliable low resistance connection Do not use alligator clips Clean the connections regularly and prevent corrosion by using a protective spray coating or Vaseline You can measure battery state of charge with a hydrometer or approximate state of charge with a voltmeter Use a digital voltmeter that can display tenths or hundredths of a volt when measuring 10 to 30 volts Make your measurements when the battery has not been charged or discharged for several hours For a deep cycle battery at 77 F 25 C use the following table Battery Voltage State of Charge 12 7 13 0 V 100 12 5 12 6 V 80 12 3 12 4V 60 12 1 12 2 V 40 11 9 12 0 V 20 975 0128 01 01 Alternators and Charging Systems A good charging system is important for the health of your batteries Poor recharging methods can quickly damage batteries Appendix C provides guidelines for recharging batteries from an alternator from AC power and from alternate energy sources Charging System Requirements Your charging system should be capable of delivering a charging current equal to 25 of the amp hour capacity of your battery For example if you have a 200 Ah battery the charging system should be able to deliver 50 A The charging system must also be able to charge each 12 V battery up to approximately 14 4 V and then drop back to a float voltage of 13 5 14
40. nual If you are using different sizes refer to the applicable code for DC grounding details Recreational Vehicle Use 8 AWG copper wire and connect it between the Chassis Ground lug and the vehicle s DC grounding point usually the vehicle chassis or a dedicated DC ground bus Chassis Ground Lug To connect the cable to the chassis ground lug 1 Make sure the inverter s On Off switch is in the Off position 2 Loosen chassis ground lug screw using a screwdriver 3 Strip 3 8 9 5 mm of insulation from one end of the cable 4 Place one end of the cable into the ground lug 5 Tighten the chassis ground lug DC Disconnects and Over Current Devices The DC circuit from the battery to the inverter must be equipped with a disconnect and over current device This usually consists of a circuit breaker a fused disconnect or a separate fuse and DC disconnect Do not confuse AC circuit breakers with DC circuit breakers They are not interchangeable The rating of the fuse or breaker must be matched to the size of cables used in accordance with the applicable installation codes The breaker or disconnect switch and fuse should be located as close as possible to the battery in the positive cable Applicable codes may limit how far the protection can be from the battery 975 0128 01 01 Connecting the DC Cables Connecting the DC Cables Do not remove the terminal nut Do not place anything between battery cable lug
41. on Display Problem Possible Cause Solution 1 AL1 Flashing Low DC input Poor DC wiring Use proper cable size and Alarm Beeping terminal voltage Poor battery condition lengths and make solid connections Charge the battery Install a new battery 2 AL2 Flashing Alarm Beeping Inverter is close to over temperature shutdown Inverter ventilation openings are obstructed Ambient temperature is too high Load applied is above the continuous operation limit Improve ventilation Make sure the inverter s ventilation openings are not obstructed Reduce the ambient temperature Reduce the load if continuous operation is required 3 E01 Flashing Fault LED Flashing Inverter is in undervoltage AL1 warning code is ignored See possible See solution under error 1 in this table Fault LED Flashing Alarm Beeping overvoltage shutdown Alarm Beeping shutdown causes under error 1 in this table 4 E02 Flashing Inverter is in High input voltage Make sure the inverter is connected to a 12 V battery Check the voltage regulation of the charging system 5 2 975 0128 01 01 Table 5 1 Troubleshooting Reference Troubleshooting Reference Error Warning no input voltage indication No power to the inverter Inverter fuse open The inverter could have been connected with reverse DC
42. ourself may result in a risk of electrical shock or fire Internal capacitors remain charged after all power is disconnected To reduce the risk of electrical shock disconnect both AC and DC power from the XPower Inverter 3000 Plus before attempting any maintenance or cleaning or working on any circuits connected to the XPower Inverter 3000 Plus Turning off controls will not reduce this risk The XPower Inverter 3000 Plus must be provided with an equipment grounding conductor connected to the AC input ground Safety Explosive gas precautions AN WARNING Explosion hazard 1 Working in the vicinity of lead acid batteries is dangerous Batteries generate explosive gases during normal operation Therefore you must read this guide and follow the instructions exactly before installing or using your XPower Inverter 3000 Plus 2 This equipment contains components which tend to produce arcs or sparks To prevent fire or explosion do not install the XPower Inverter 3000 Plus in compartments containing batteries or flammable materials or in locations that require ignition protected equipment This includes any space containing gasoline powered machinery fuel tanks as well as joints fittings or other connections between components of the fuel system 3 To reduce the risk of battery explosion follow these instructions and those published by the battery manufacturer and the manufacturer of the equipment in which the battery is ins
43. pecific legal rights You may have other rights which may vary from state to state or province to province Warning Limitations On Use Please refer to your product manual for limitations on uses of the product SPECIFICALLY PLEASE NOTE THAT THE XPOWER INVERTER 3000 PLUS SHOULD NOT BE USED IN CONNECTION WITH LIFE SUPPORT SYSTEMS OR OTHER MEDICAL EQUIPMENT OR DEVICES WITHOUT LIMITING THE GENERALITY OF THE FOREGOING XANTREX MAKES NO REPRESENTATIONS OR WARRANTIES REGARDING THE USE OF THE XANTREX XPOWER INVERTER 3000 PLUS IN CONNECTION WITH LIFE SUPPORT SYSTEMS OR OTHER MEDICAL EQUIPMENT OR DEVICES Please note that the XPower Inverter 3000 Plus is not intended for use as an uninterruptible power supply and Xantrex makes no warranty or representation in connection with any use of the product for such purposes 975 0128 01 01 WA 3 Warranty and Product Information Return Material Authorization Policy Before returning a product directly to Xantrex you must obtain a Return Material Authorization RMA number and the correct factory Ship To address Products must also be shipped prepaid Product shipments will be refused and returned at your expense if they are unauthorized returned without an RMA number clearly marked on the outside of the shipping box if they are shipped collect or if they are shipped to the wrong location When you contact Xantrex to obtain service please have your instruction manual ready for reference and be prepared
44. re for example 50 A for 2 hours or 200 A for 1 2 hour but usually the capacity figure given is only accurate at the specified rate 20 hours To calculate the battery capacity you require read Estimating Battery Requirements on page B 3 and Battery Sizing Example on page B 4 and then complete the Battery Sizing Worksheet on page B S Estimating Battery Requirements To determine how much battery capacity you need l Determine how many watts are consumed by each appliance that you will operate from the XPower 3000 You can normally find the watt rating labelled on the product If only the current draw is given multiply it by 115 to get the power consumption in watts Estimate how many hours each appliance will be operating each day Calculate the daily watt hours needed for each appliance Add the total number of watt hours needed for all the appliances and multiply it by the number of days between charges Divide the total watt hours of AC load between charges by 10 This gives the battery Ah used between charges Double the total Ah used between charges to get the recommended battery size in Ah See the battery sizing example that follows 975 0128 01 01 Battery Types Battery Sizing Example This battery sizing example illustrates a typical calculation assuming an opportunity to charge the batteries every three days Appliance Daily watt hours needed for this appliance A xB
45. s Ground Cable Refer to Table 3 2 to plan the size of the chassis ground cable that runs from the DC grounding point to the chassis ground screw on the inverter s DC panel Table 3 2 Recommended Chassis Ground Cable sizes Application Chassis ground cable size Stranded cable is recommended Recreational Vehicle No 8 AWG Note There are no restrictions on length for the chassis ground cable 3 6 975 0128 01 01 Designing Your Installation Calculating Fuse Circuit Breaker Size Because your batteries can provide thousands of amps of short circuit current you need fuses or circuit breakers that can safely withstand the short circuit current that the batteries can produce To select the correct fuse type and size 1 Determine the total short circuit current rating for your batteries For example e Ifyou are using one battery to power your inverter and its short circuit current rating is 500 A the total short circuit current rating is 500 A e If you are powering your inverter with two 12 V batteries connected in parallel and each battery has a short circuit current rating of 500 A the total short circuit current rating is 1000 A e If you are powering your inverter with two 6 V batteries connected in series and each battery has a short circuit current rating of 500 A the total short circuit current rating is 500 A Important For batteries connected in parallel the total short circuit current rating
46. talled Precautions When Working With Batteries AN WARNING Explosion or fire hazard 1 Follow all instructions published by the battery manufacturer and the manufacturer of the equipment in which the battery is installed 2 Make sure the area around the battery is well ventilated Never smoke or allow a spark or flame near the engine or batteries Use caution to reduce the risk or dropping a metal tool on the battery It could spark or short circuit the battery or other electrical parts and could cause an explosion vi 975 0128 01 01 10 Safety Remove all metal items like rings bracelets and watches when working with lead acid batteries Lead acid batteries produce a short circuit current high enough to weld metal to skin causing a severe burn Have someone within range of your voice or close enough to come to your aid when you work near a lead acid battery Have plenty of fresh water and soap nearby in case battery acid contacts skin clothing or eyes Wear complete eye protection and clothing protection Avoid touching your eyes while working near batteries If battery acid contacts skin or clothing wash immediately with soap and water If acid enters your eye immediately flood it with running cold water for at least twenty minutes and get medical attention immediately If you need to remove a battery always remove the ground terminal from the battery first Make sure all accessories ar off so you don
47. ter 3 Installation provides information on cables and fuses to help you plan for your installation and provide procedures for installing the inverter Read the entire chapter before beginning the installation procedures so that you can plan an installation that is suited to your power needs Designing Your Installation Before doing anything else you need to determine how you are going to use your inverter and then design a power system that will give you maximum performance The more thorough your planning the better your power needs will be met In particular you will need to e Be aware of installation codes e Calculate your battery requirements e Choose an effective charging system e Choose an appropriate location e Calculate the cable size for your inverter e Select the correct fuses or circuit breakers Study Figures Configuration for Normal Loads on page 3 2 and Configuration for Heavy Loads on page 3 2 for an example of a setup for normal or heavy loads in a vehicle When you have decided upon your configuration then you can calculate battery requirements Installation Figure 3 2 3 2 DICONNECT SWITCH GROUND TO VEHICLE CHASSIS FUSE OR CIRCUIT BREAKER TO VEHICLE DEEP CYCLE AUXILIARY BATTERY VEHICLE STARTING BATTERY GROUND TO VEHICLE CHASSIS GROUND TO VEHICLE CHASSIS FUSE OR CIRCUIT BREAKER TODC LOADS DEEP
48. tery This is the last cable connection you make If the disconnect switch or breaker is not turned off a spark is normal when the connection is made Use a wrench to tighten to a torque of 216 240 inch pounds 24 27 Nm Test that the cable is secure Attach the DC terminal covers Before proceeding double check that you have connected the cables properly positive to positive negative to negative Turn on the battery disconnect switch or breaker If you have installed a battery selector switch use it to select one of the batteries or battery banks house bank preferred over start bank Move the inverter s On Off switch to the On position Check the input voltage display It should read between 12 and 13 V depending on the condition of the battery If it does not check your battery and the connection to the inverter and the state of charge of the battery Operation Chapter 4 explains how to operate the inverter efficiently and effectively Specifically this chapter e Gives procedures for operating the inverter from the front panel e Discusses operating limits and inverter loads e Discusses battery charging frequency e Provides information about routine maintenance Turning the Inverter On and Off The On Off switch on the inverter s front panel turns the control circuit in the inverter on and off To turn the inverter on and off from its front panel e Move the On Off switch to the On position to turn the invert
49. uring charging This will increase the alternator s charging rate at higher battery voltages and ensure more rapid and complete charging Using a High Output Alternator Heavy duty alternators rated from 100 140 A can replace standard alternators and produce the higher current and voltage required to charge multiple battery systems They are available from RV and auto parts suppliers C 2 975 0128 01 01 Charging From AC Power Charging From AC Power When recharging from AC power use a good quality charger or RV converter that meets the requirements outlined in Charging System Requirements on page C 1 Do not use chargers intended for occasional recharging of automotive starting batteries These chargers are not intended for continuous use Charging From Alternative Energy Sources You can also charge your batteries from alternative energy sources such as solar panels wind or hydro systems Make sure you use the appropriate battery charge controller for your particular energy source AN CAUTION Never operate the inverter directly from an energy source such as a solar panel The inverter must be connected to a battery or a well regulated high current DC power supply to work properly 975 0128 01 01 C 3 Warranty and Product Information Warranty What does this warranty cover This Limited Warranty is provided by Xantrex Technology Inc Xantrex and covers defects in workmanship and materials in your XPo
50. usable energy to your load For safe and efficient operation you will need to calculate cable sizes for your DC input cables from the battery to inverter one way e Chassis ground cable from the grounding point to the chassis ground lug on the inverter s DC panel See Figure 3 4 DC Panel Connections on page 3 11 A WARNING Use only copper wire rated 90 C minimum Never use a DC input cable longer than specified in Table 3 1 A longer cable can potentially generate enough heat to start a fire or result in poor inverter performance Calculating Size of DC Input Cables 975 0128 01 01 Refer to Table 3 1 to plan the DC cabling e Keep all cables as short as possible and ensure that each cable between the inverter and the battery is no longer than 10 feet 3 m Do not use aluminum cable It has about 1 3 more resistance than copper cable of the same size and it is difficult to make good low resistance connections to aluminum wire e We recommend that you use oil resistant cable Installation Table 3 1 Recommended DC Input Wire Sizes amp Lengths RV Recreational Vehicle Cable length Battery to Inverter Minimum Cable Size Maximum Battery one way Fuse Size 5 feet 1 5 m or less No 4 0 AWG 450 Adc 10 feet 3 m 350 MCM 450 Adc Note Never use a cable longer than 10 feet 3 m Appropriate size cable can be bought at a welding supply house Calculating Size of Chassi
51. vice If your product requires troubleshooting or warranty service contact your merchant If you are unable to contact your merchant or the merchant is unable to provide service contact Xantrex directly at Telephone 1 800 670 0707 toll free North America 1 360 925 5097 direct Fax 1 800 994 7828 toll free North America 1 360 925 5143 direct Email customerservice xantrex com Direct returns may be performed according to the Xantrex Return Material Authorization Policy described in your product manual For some products Xantrex maintains a network of regional Authorized Service Centers Call Xantrex or check our website to see if your product can be repaired at one of these facilities 975 0128 01 01 WA 1 Warranty and Product Information What proof of purchase is required In any warranty claim dated proof of purchase must accompany the product and the product must not have been disassembled or modified without prior written authorization by Xantrex Proof of purchase may be in any one of the following forms The dated purchase receipt from the original purchase of the product at point of sale to the end user or The dated dealer invoice or purchase receipt showing original equipment manufacturer OEM status or The dated invoice or purchase receipt showing the product exchanged under warranty What does this warranty not cover This Limited Warranty does not cover normal wear and tear of the product or costs related to
52. wer Inverter 3000 Plus This warranty period lasts for 12 months from the date of purchase at the point of sale to you the original end user customer You require proof of purchase to make warranty claims What will Xantrex do Xantrex will at its option repair or replace the defective product free of charge provided that you notify Xantrex of the product defect within the Warranty Period and provided that Xantrex through inspection establishes the existence of such a defect and that it is covered by this Limited Warranty Xantrex will at its option use new and or reconditioned parts in performing warranty repair and building replacement products Xantrex reserves the right to use parts or products of original or improved design in the repair or replacement If Xantrex repairs or replaces a product its warranty continues for the remaining portion of the original Warranty Period or 90 days from the date of the return shipment to the customer whichever is greater All replaced products and all parts removed from repaired products become the property of Xantrex Xantrex covers both parts and labor necessary to repair the product and return shipment to the customer via a Xantrex selected non expedited surface freight within the contiguous United States and Canada Alaska and Hawaii are excluded Contact Xantrex Customer Service for details on freight policy for return shipments outside of the contiguous United States and Canada How do you get ser
53. you will be using them between charges Once you know how much power you will be using you can determine how much battery capacity you need We recommend that you purchase as much battery capacity as possible Consult Appendix B for a detailed explanation of how to determine the appropriate number and size of batteries for your needs AN CAUTION The inverter must only be connected to a 12 V battery system It will not operate if connected to a 6 V battery and will be damaged if connected to a 24 V battery Choosing an Effective Charging System The charging system must be appropriate for your particular installation A well designed charging system will ensure that power is available when you need it and that your batteries remain in top condition Inadequate charging will degrade system performance and the wrong type of charger will reduce battery life Consult Appendix C Alternators and Charging Systems for information about choosing an effective charging system 975 0128 01 01 3 3 Installation Choosing an Appropriate Location WARNING The inverter contains components that tend to produce arcs or sparks To prevent fire or explosion do not install the inverter in compartments containing batteries or flammable materials or in locations that require ignition protected equipment WARNING To reduce the risk of fire do not cover or obstruct the ventilation openings Do not install the inverter in a zero
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